Cushioned carabiner clip

ABSTRACT

The present invention relates to an improved carabiner system, including an impact-dampening cushion around the external surface of the frame for cushioning damage during a fall or collision and to reduce sound from loose or swinging carabiner collisions. Additional surface routing and through holes provide improved register between the carabiner frame and the over-molded cushion layer.

INCORPORATION BY REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.15/588,551, filed on May 5, 2017, which claims priority to U.S.Provisional Application No. 62/331,980, filed May 5, 2016. All of theabove applications are incorporated herein by reference in theirentirety.

BACKGROUND Field of the Invention

This patent document relates to a fastening clip and methods ofmanufacturing and use thereof. This patent document relates moreparticularly to a carabiner clip including a cushion layer to reduceimpact and damage from impact.

Description of the Related Art

A carabiner is a mechanical device used to link rope, slings, orclimbing aids together. Carabiners are popular in rope-intensiveactivities such as climbing, boating, sailing, farming/ranching,skydiving and aerial sports, construction, trucking, and safety systems.Carabiners are also used in less demanding roles as key rings,connecting water bottles to backpacks, holding electrical cords,securing animal leashes or restraints, or to quickly construct tents,canopies, or clotheslines.

Carabiners typically consist of a rigid loop with a spring-loaded gateused to quickly and removably attach two components or a singlecomponent to a rope. Most carabiners include a frame, a gate, a hinge,and a spring. A traditional carabiner is generally a C-shaped frameconnected to a spring-loaded, hinged gate. When the gate is closed, theC-shaped frame and gate form a closed loop around an interior cavity.When the gate is open, the opening between the gate and the C-shapedframe allows insertion of a rope or loop into the interior cavity. Aspring provides force to return the gate to the closed position toprevent unintended detachment.

Carabiners intended to secure heavy items, valuable property, or humanbodies are constructed from stronger materials and thicker components ifintended for carabiners. Lighter materials and thinner carabiners may beused for less intensive activities unrelated to safety. Strongermaterials and thicker frames result in heavier and larger carabiners.

The inventors here have found that the carabiners intended for use incertain activities can be unwieldy and cause injury and/or damage whenreleased under tension or dropped. As an example, a heavy, steelcarabiner used in recreational boating to connect moorings or tow ropescan easily crack or chip the fiberglass hull of an expensive boat ifdropped or released. Additionally many climbers or construction workershave experienced unpleasant bumps and bruises from loose carabinercollisions. Accordingly, it is here recognized that a continued needexists to overcome and improve upon such shortcomings in conventionalcarabiners. In order to address the above-described exemplary problems,and other similar problems, what is needed is a cushioned carabiner thatwill absorb some of the shock of impact and dampen the noise produced bya loose carabiner without sacrificing durability or functionality,thereby providing enhanced functionality, safety, and convenience to theuser.

SUMMARY

Various aspects are described in connection with an illustrativeimplementation of the cushioned carabiner disclosed herein. The variousaspects are disclosed in the written specification including thedrawings, and claims, and may be combined to form claims for a device,apparatus, system method of manufacture and/or use in any way,consistent with the teachings herein, without limitation.

The cushioned carabiner comprises a uniquely configured and constructedcarabiner including a cushion layer attached to the spine of thecarabiner frame. In some aspects, the cushion layer covers most or allexposed (internal and external) surfaces of the frame, excluding thoseareas that interfere with gate or mechanical movement. In some aspects,the cushion layer is molded to the frame and covers the external surfaceof the frame, cushioning the external areas likely to impact in acollision if dropped or swung. In some aspects the cushion layer coversonly specific external surfaces of the frame, while in other aspects,the cushion may cover most or all of the outward facing surfaces of theframe. In some aspects, the internal surface of the carabiner frame mayremain uncovered by the cushion layer so that the internal surface ofthe carabiner remains durable and low-friction for sliding ropes. Inother aspects, some or all of the internal surfaces (facing toward theinterior cavity) of the carabiner frame may include a cushion layerwhile the external surfaces remain exposed (or cushionless). In someaspects, the gate may also include a cushion layer on the externalsurface, on the interior surface, or on all surfaces.

In some aspects, the cushion layer is thick and soft enough tosignificantly reduce the energy of impact. In other aspects, the cushionlayer is intended to only dampen sound from clanging metal or to providesome level of external friction, so the cushion layer may be relativelythin or composed of alternate materials. In some aspects, the cushionlayer is manufactured from silicon, rubber, synthetic rubber, plastic,plastic alternatives, fabric, plant matter, paper, recycled materials,cellulose, bioisoprene, resin, or any other cushioning material. In someaspects the frame and/or gate may be formed of the same or differentmaterials, including (but not limited to) any of steel, stainless steel,316 stainless steel, iron, aluminum, titanium, tin, zinc, copper, brass,bronze, wood, plastic, carbon fiber, and composite. In some aspects, theframe and/or gate are electro-polished or electro-coated. In someaspects, the frame and/or gate may include contours, grips, oradditional curves. In some aspects, the frame and/or gate are forged,molded, carved, rolled, or pressed. In some aspects the frame isco-molded with the cushion layer.

In various aspects, the carabiner can be formed in a variety ofalternate shapes to optimize performance for specific purposes. In someaspects, the carabiner includes a locking mechanism, a wire gate orhollow gate, multiple gates providing access to multiple interiorcavities, or multiple internal cavities accessed through a single gate.In another aspect, the carabiner frame may include an additional closedloop without a gate for securing ropes that are tied to the loop ratherthan clipped with a gate. In another aspect, the carabiner may includetwo or more separately-gated internal cavities. In further aspects, acarabiner may include multiple separately gated interior cavitiesconnected by a rigid connecting structure. In still other aspects, acarabiner system may include multiple separate carabiners connected by aflexible rope, strap, or fastener. In another aspect, the hinge may bepivoted and the gate may instead open outward or to the side. In anotheraspect, various lock mechanisms may be provided to secure the gate andavoid inadvertent release.

Various alternative implementations of the foregoing aspects aredisclosed. The foregoing various aspects may be combined in any mannerwithout limitation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a right side view of an exemplary cushioned carabiner in theclosed position, the cushioned carabiner comprising a cushion layerdisposed on the external surface of the frame.

FIG. 2 is a right side view of an exemplary cushioned carabiner in theopen position, the cushioned carabiner comprising a cushion layerdisposed on the external surface of the frame.

FIGS. 3 and 4 are right and left side photographs of an exemplarycushioned carabiner frame before the cushion layer is connected,revealing the underlying structure. The depicted carabiner frame isshown without the gate and hinge.

FIGS. 5 and 6 are right and left side photographs of an exemplarycushioned carabiner frame. The depicted carabiner frame is shown withoutthe gate and hinge

FIGS. 7 and 8 are right and left side photographs of an exemplarylocking cushioned carabiners before the cushion layer is connected,revealing the underlying structure. The depicted carabiners include ascrew-type locking mechanism and the gate is in the closed position.

FIG. 9 is a left side view of an exemplary locking cushioned carabiner.The depicted carabiner includes a screw-type locking mechanism and thegate is in the open position.

FIGS. 10 and 11 are alternate perspective views of a cushioned carabinerframe.

FIG. 12 is a view of an alternate double-crotch cushioned carabinerframe.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The features, aspects and advantages are described below with referenceto the drawings, which are intended to illustrate but not to limit theinvention. In the drawings, like reference characters denotecorresponding features consistently throughout the drawings. FIGS. 1-11illustrate various aspects of an embodiment of the cushioned carabiner100. It should be understood, however, that the teachings herein are notlimited to any particular carabiner and are applicable to otherfasteners.

As illustrated in FIGS. 1-11, the carabiner frame 110 is a generallyC-shaped metal piece with a gate opening 113 between the two ends 111,112 of the frame 110. The proximal end 121 of a gate 120 sized anddimensioned to span the gate opening 113 is affixed to a proximal end111 of the frame 110 by a hinge 130 (comprising a hinge pin or rivet 132inserted through both gate hinge hole 124 and frame hinge hole 133), andthe distal end 122 of the gate 120 rests against or is otherwise inrelative proximity to the nose or distal end 112 of the frame 110.Together the frame 110 and gate 120 form a closed loop around aninterior cavity 101. The frame 110 and gate 120 each include externalsurfaces 102 and internal surfaces 103.

An inward force applied to the gate 120 can pivot the gate 120 aroundthe hinge 130, creating a gap between the distal end 122 of the gate 120and the nose 112 of the frame 110. While the gate 120 is open, ropes orloops can be fed through the gate opening 113, and when the inward forceis removed, a hinge spring 131 (not shown) applies pressure to returnthe gate 120 to its rest position and close the carabiner 100, securingany loops or ropes in the interior cavity 101. At rest, the hinge spring131 applies pressure to the gate 120, pressing it outward from theinterior cavity 101 so that the distal end 122 of the gate 120 ispressed against or rests against a notch 117 in the nose 112 of theframe 110, keeping the gate 120 from swinging open in response to anyoutward force applied from the interior cavity 101 (such as by a clippedrope). A lock 140 can be built into the gate, the frame, or the hingethat maintains the gate in a closed position.

The cushion layer 150 can be attached directly to the surface of theframe 110 with adhesive (not shown), but surface texturing 118 (e.g.,grooves, holes, or other surface adjustments that increase contact areaand corners between the cushion layer 150 and the frame 110 or gate 120)significantly improves the connection and prevents peeling and damage.Through holes 119 allow the cushion layer 150 to flow through the frame110, significantly improving durability and attachment of the cushionlayer 150.

With reference to FIGS. 1 and 2, carabiner frame 110 and/or gate 120 maybe formed from a variety of metals, alloys, and rigid materialsincluding, but not limited to steel, stainless steel, 316 stainlesssteel, iron, aluminum, titanium, tin, zinc, copper, brass, bronze, wood,plastic, resin, carbon fiber, and composite. The frame 110 and/or gate120 may be formed of the same or different materials,. Similarly theelements of the hinge 130 and lock 140 may be made from the samematerials as the frame or from a different material. In some aspects,the frame 110 and/or gate 120 are electro-polished or electro-coated toimprove corrosion resistance and surface texture. The frame and gate110, 120 of the carabiners may be molded into the desired shape, may bepowder-pressed, or shaped by bending alloy rods into the desired shape.Fine-tuning the curve and cross-section, forming the surface-texture118, through holes 119, gate hinge hole 124, or frame hinge hole 133 maybe performed by machine stamping or machining. After the properstructure is achieved, these elements may be heat-treated to increasethe strength thereof. The frame may be generally C-shaped, which in thepresent context equates generally to a loop missing a section, similarto the letter C. The frame may also encompasses any style orconfiguration of carabiner body, including at least oval, D-shaped,offset D-shaped, pear shaped, S-hook, double-gate or multi-gate, or anyother style of quick-fastener.

The frame 110 extends from the proximal end 111 to the distal end ornose 112. The gap between the proximal end 111 and the distal end 112 ofthe frame 110 is the gate opening 113, which is spanned by gate 120. Theproximal end 111 of the frame 100 includes a frame hinge hole 133 forconnecting the hinge 130 with a hinge pin or rivet 132. The nose 112 mayinclude a notch (or a hook or fastener) 117 for securing a gate pin orother securing mechanism 123 at the distal end 122 of the gate 120. Thebend closest to the proximal end 111 is the crotch 115. The bend closestto the distal end or nose 112 is the basket. The spine 114 is the long,sometimes reinforced section between the crotch 115 and the basket 116.The spine 114 may be reinforced or thicker to provide extra strength orsupport. In some embodiments, the frame 110 may include a concavesection between the crotch 115 and the spine 114.

The gate 120 comprises a proximal end 121 connected to the frame 110 bythe hinge 130 and a distal end 122. An inward force applied to the gate120 will pivot the gate 120 about the hinge 130, providing a gap betweenthe distal end 122 of the gate 120 and the distal end 112 of the frame110, through which the interior cavity 101 can be accessed. An outwardforce applied from within the interior cavity 101 (such as by a rope orloop) presses the distal end 122 of the gate 120 against a notch orother feature of the nose 112, transferring stress to the spine 114. Thegate 120 may be straight, concave, convex, or a combination of concaveand convex. A convex gate provides a wider opening for access to theinterior cavity 101 while a concave gate makes it easier to apply thegate opening force directly with a rope or loop.

The hinge 130 comprises a hinge pin or rivet 132 inserted through a gatehinge hole 124 at the proximal end 121 of the gate 120 and the framehinge hole 133 of the frame 110. The gate 120 pivots about the hinge pin132, providing an opening for access to the interior cavity 101.Alternatively hinge pin 112 can be a screw, a ball-and-socket joint, orany other pivotable attachment mechanism. Hinge 130 may also include ahinge spring 131 (not shown). Hinge spring 131 may be either a housedspring or cantilevered spring. A housed spring and piston requires ahollow cavity in the gate member, but cantilevered springs may be morecost-effective and stronger. Hinge spring 131 applies a force to returngate 120 to its default position. In most cases, the default position isa closed gate 120, but in some specific instances, a default open gate120 may be preferable. In alternate instances, the hinge may openinward, outward, or laterally.

FIGS. 5-6 depict an exemplary cushioned carabiner frame 110 including acushion layer 150 attached to the frame 110. The cushion layer 150 maybe molded directly over the frame 110. In some instances, an adhesivemay be applied between the frame 110 and the cushion layer 150 toimprove the connection and durability of the carabiner 100.

In FIGS. 5 and 6, a single continuous cushion layer 150 is applied tothe entire external surface 102 of the frame 110, leaving the internalsurface 103 exposed. This configuration cushions the carabiner clip frommost angles without interfering with gate or lock movement. Additionallythe exposed internal surface 103 retains the benefits of the durablemetal (or other material) surface, including durability and low frictionfor ropes. It should be understood that in other embodiments, thecushion layer 150 may coat both the external surface 103 and theinternal surface 102. In still other embodiment, only the internalsurface 103 is covered by a cushion layer 150, while the externalsurface 102 remains exposed. A fully cushioned carabiner frame 110 orinternally cushioned carabiner frame may be preferable to avoid leavingscratches or marks or simply to reduce clanging between metal piecesduring movement.

The cushion layer 150 may be manufactured from silicon, rubber,synthetic rubber, plastic, plastic alternatives, fabric, plant matter,paper, recycled materials, cellulose, bioisoprene, resin, or any othermaterial. It may be preferable to injection-mold the cushion layer 150around the frame 110 or gate 120. In some instances, the carabiner frame110 and the cushion-layer 150 may be co-molded through a dual-injectionprocess, quickly and reliably producing a 2-material product.

In some instances, the carabiner frame and cushion layer 150 may provideadditional benefits, beyond impact-absorption and noise-dampening. Thecushion layer 150 or carabiner frame 110 may be made of conductivematerials, and as a weight applied to the carabiner 100 slightlyelongates the frame 110, the conductive cushion-layer 150 or theconductive carabiner frame 110 functions as a strain gauge, reading thechange in electrical properties (resistance, resistivity, conductivity)and translating that change of state to estimate the load force. Theestimated load force or the electrical properties changes may betransmitted to or detected by an outside computer. The conversion mayoccur outside of the carabiner 100. In another embodiment, the cushionlayer is intentionally formed of an insulating layer to preventelectrical conductivity, even if the underlying carabiner frame is madeof a conductive material.

Alternatively the cushion layer may be formed of a material thatmeasures G-force, and once a certain G-force level is experienced, thecushion layer or a part thereof changes color. In some instances, thisG-force cushion layer provides additional security and confidence byaffirmatively indicating when a significant impact renders a carabinerunreliable for future use.

Returning now to FIGS. 3 and 4, carabiner frames 110 similar to thosedepicted in FIGS. 5 and 6 are shown without the cushion layer 150. Theframe 110 includes a surface texture or routing 118 and through holes119 to increase the connection between frame 110 and cushion layer 150.The surface texture increases the contact area and the “grip” betweenthe frame 110 and the cushion layer significantly, and the through holes119 allow an injection-molded cushion layer 150 to flow through theframe 110, creating loops through the frame that further secure thecushion layer 150 in place and prevent peeling and prolonging the usefullife of the carabiner. Placing through holes 119 at or near the variouscurved segments of the carabiner clip improves adhesion near thosepoints. In the present embodiment, 3 through holes 119 pass through theframe within the surface routing 118. Two of the through holes arelocated on opposite sides of the crotch, while the third through-hole islocated between the nose 112 and the basket 116. It should be noted thatthrough-holes 119 reduce the strength of the frame 110 in the areaimmediately surrounding the through-hole, so through-holes should not beplaced in high-strain areas if avoidable. In some embodiments,through-holes should not be included along the spine.

As shown in FIGS. 7-9, some carabiners may include a lock 140 to securethe gate 120 relative to the frame 110. The lock 140 ensures that gate120 will remain closed until intentionally opened, and reduces the riskto health, life, and property. The lock of FIGS. 7-9 is a screw-typelock, which includes a screw-type rotating fastener, which can berotated multiple times about the gate 120, forming a rigid sleeve thatcovers both a portion of the gate 120 and a portion of the frame 110 tostrengthen the closed loop. Alternately, some twist-type gate locksrequire that the gate element 140 be pressed against a lock spring (notshown), rotated about the gate 120, and then a pressure applied to thegate 120 will cause the gate 120 to pivot about hinge 130. Other typesof gate locks may include ball-lock mechanisms and additional latches orsupports.

As shown in FIG. 12, an alternate embodiment of the present inventionmay include a double crotch cushioned carabiner frame, including a firstcrotch 115 a and a second crotch 115 b. The two separate crotches 115 a,115 b enable the carabiner frame 110 to secure two ropes or loopssimultaneously, minimizing friction and tangling between the two ropeswith the two discrete crotches 115 a, 115. One of ordinary skill in theart would understand that a multi-crotch cushioned carabiner frame couldinclude more than two crotches without departing from the presentinvention. Additionally a further alternate embodiment not shownincludes a multi-basket, including more than one basket 111 a, 111 b. Insome instances a carabiner may include multiple baskets 111 a, 111 b andmultiple crotches 115 a, 115 b. Each crotch may be open to the interiorof the carabiner clip or may be wholly looped by a reinforced element.The multiple crotch and multiple basket embodiments require more complexsurface texture or routing 118 and potentially additional through-holes119 to secure the cushion layer 150 to the frame 110.

Although various aspects are herein disclosed in the context of certainpreferred embodiments, implementations, and examples, it will beunderstood by those skilled in the art that the present inventionextends beyond the specifically disclosed embodiments to otheralternative embodiments and/or uses of the inventive aspects and obviousmodifications and equivalents thereof. In addition, while a number ofvariations of the aspects have been noted, other modifications, whichare within their scope, will be readily apparent to those of skill inthe art based upon this disclosure. It should be also understood thatthe scope this disclosure includes the various combinations orsub-combinations of the specific features and aspects of the embodimentsdisclosed herein, such that the various features, modes ofimplementation and operation, and aspects of the disclosed subjectmatter may be combined with or substituted for one another. Thus, it isintended that the scope of the present invention herein disclosed shouldnot be limited by the particular disclosed embodiments orimplementations described above, but should be determined only by a fairreading of the claims.

Similarly, this method of disclosure, is not to be interpreted asreflecting an intention that any claim require more features than areexpressly recited in that claim. Rather, as the following claimsreflect, inventive aspects lie in a combination of fewer than allfeatures of any single foregoing disclosed embodiment. Thus, the claimsfollowing the Detailed Description are hereby expressly incorporatedinto this Detailed Description, with each claim standing on its own as aseparate embodiment.

What is claimed is:
 1. A carabiner, comprising: a frame having aproximal end and a distal end at opposite ends of an elongated sectionwith a gate opening between the proximal end and the distal end, theframe having an internal surface generally defining an interior cavityand an external surface opposite the internal surface; a gate pivotallyattached to the proximal end of the frame to span the gate opening andconfigured to open and close for access to the interior cavity of theframe, the gate and the frame together forming a closed shape when thegate is closed; and a cushion layer secured to and covering a portion ofthe external surface of the frame, wherein the cushion layer does notcover the internal surface of the frame.
 2. The carabiner of claim 1,wherein the entire internal surface of the frame is exposed.
 3. Thecarabiner of claim 2, wherein the frame further comprises: a spinepositioned opposite the interior cavity from the gate opening; a firstconcave curved portion connecting the spine to the proximal end; and asecond concave curved portion connecting the spine to the distal end. 4.The carabiner of claim 3, wherein the cushion layer covers the externalsurface of the spine.
 5. The carabiner of claim 3, wherein a singlecushion layer continuously covers the external surface of the frame fromthe first concave curved portion to the second concave curved portion.6. The carabiner of claim 5, wherein the frame includes at least onegroove and the material of the cushion layer fills and attaches to theat least one groove to increase the bond between the cushion layer andthe frame.
 7. The carabiner of claim 6, further comprising one or morethrough-holes extending through the frame, and the material of thecushion layer loops through the at least one through-hole.
 8. Thecarabiner of claim 5, wherein: a first groove is formed on a first sidesurface of the frame between the internal surface and the externalsurface and the material of the cushion layer fills and attaches to thefirst groove, strengthening the bond between the cushion layer and theframe; and a second groove is formed on a second side surface of theframe between the external surface and the internal surface, the secondside surface being opposite the first side surface, and the material ofthe cushion layer fills and attaches to the second groove, strengtheningthe bond between the cushion layer and the frame.
 9. A carabiner,comprising: a frame comprising: a proximal end and a distal end atopposite ends of an elongated section; a gate opening between theproximal end and the distal end; an internal surface generally definingan interior cavity and an external surface opposite the internal surfacea spine positioned opposite the interior cavity from the gate opening; afirst concave curved portion connecting the spine to the proximal end;and a second concave curved portion connecting the spine to the distalend; a gate pivotally attached to the proximal end of the frame to spanthe gate opening and configured to open and close providing access tothe interior cavity of the frame, the gate and the frame togetherforming a closed shape when the gate is closed; and a single continuouscushion layer secured to and covering the external surface of the framefrom the first concave curved portion to the second concave curvedportion, wherein the cushion layer does not cover the internal surfaceof the frame and the entire internal surface is exposed.
 10. Thecarabiner of claim 9, wherein: a first groove is formed on a first sidesurface of the frame between the internal surface and the externalsurface and the material of the cushion layer fills and attaches to thefirst groove, strengthening the bond between the cushion layer and theframe; and a second groove is formed on a second side surface of theframe between the external surface and the internal surface, the secondside surface being opposite the first side surface, and the material ofthe cushion layer fills and attaches to the second groove, strengtheningthe bond between the cushion layer and the frame.
 11. The carabiner ofclaim 10, wherein the frame includes a first through-hole between theproximal end and the first concave curved portion, a second through-holebetween the distal end and the second concave curved portion, and athird through-hole between the first concave curved portion and thespine, and the material of the cushion layer loops through each of thefirst, second, and third through-holes.
 12. The carabiner of claim 11,wherein each of the first, second, and third through-holes is alignedwith and connects the first groove to the second groove.
 13. Thecarabiner of claim 9, wherein the frame includes: a first through-holebetween the proximal end and the first concave curved portion; a secondthrough-hole between the distal end and the second concave curvedportion; and a third through-hole between the first concave curvedportion and the spine; wherein each of the through-holes extend from afirst side surface of the frame between the internal surface and theexternal surface to a second side surface of the frame between theexternal surface and the internal surface, the second side surface beingopposite the first side surface.
 14. The carabiner of claim 13, wherein:a first groove is formed on the first side surface of the frame; and asecond groove is formed on the second side surface of the frame; whereinthe material of the cushion layer fills the first and second grooves andloops through each of the first, second, and third through-holes,strengthening the bond between the cushion layer and the frame.